Hanger construction for refractory roof



A. J. DARKE HANGER CONSTRUCTION FOR REFRACTORY ROOF Filed Sept. 21, 1962 May 4, 1965 2 Sheets-Sheet 1 INVENTOR ANDREW J. DARKE May 4, 1965 A. J. DARKE HANGER CONSTRUCTION FOR REFRACTORY ROOF Filed Sept. 21 1962 2 Sheets-Sheet 2 FIG, 3

FIG. 2

INVENTOR. ANDREW J. DARKE United States Patent 3,181,487 HANGER NSTRUCTIGN FOR REFRACTORY RGOF Andrew J. Burke, Garfield Heights, Ghio, assignor to North American Refractories Company Filed Sept. 21, 1962, Ser. No. 225,329 11 Claims. ((Zl. nth-$9) The present invention relates generally to hangers and more particularly to hanger assemblies for supporting and anchoring monolithic refractory roof structures.

The monolithic type of refractory roof construction has often been found more satisfactory for furnaces and similar applications than refractory brick previously used. In .a monolithic construction a refractory material is pounded or cast against a form and around hanger assemblies. The hanger assemblies anchor and support the solidified monolithic refractory material to the steel structure of the furnace. The monolithic refractory material is permitted to dry naturally, or with the application of heat, and then is fired by the heat of the furnace at temperatures in excess of 2,000 F. This firing produces the finished monolithic roof structure.

The use of the monolithic refractory material in form ing the interior surfaces of furnaces, soaking pits, and other structures has found wide acceptance because the monolithic refractory may be formed readily into desired curvatures or slopes. Moreover, the monolithic nature of the finished construction provides a strong and long-lasting structure having a greatly reduced tendency to spall. For many applications, construction of mono lithic refractory material supported by hanger assemblies has proved very successful because of a big drop in main tenance and repairs. However, many of the prior hanger assemblies which support and anchor sucha monolithic construction have failed under the stresses and strains resulting when the furnace is put in use.

One prior proposed hanger is constructed of two pieces, an anchor and a hanger casting. The anchor is an elongated, ribbed member cast from refractory material and is secured to a structural steel of the furnace by the metal hanger casting. The metal casting has a pair of inwardly projecting flanges which slip under rib projections on the sides of the refractory anchor. The weight of the furnace roof is transmitted to the metal hanger casting through the relatively small cross-sectional area of the rib projection. these rib projections breaking off so that particular anchor no longer carries its share of the roof load.

The hanger assembly of the present invention is not nearlyas suceptible to breakage as are prior hangers. The hanger assembly of the invention is essentially a three-piece construction. The present hanger assembly includes a refractory anchor having a lower ribbed portion around which the monolithic refractory material is cast or pneumatically packed. The anchor further ineludes an upper hanger portion which is secured to an I-beam or other furnace support structure by a pair of hanger plates. The hanger portion of the refractory anchor includes first and second oppositely disposed face surfaces from which firstand second support lugs project respectively. The hanger plates include openings which receive the support lugs. The hanger portion of the refractory anchor further includes a pair of inwardly projecting protrusions which define a T-shaped groove. The hanger plates are further provided with pairs of tabs above the lug receiving openings. The tabs align with the inwardly projecting protrusions of the anchor so that the entire unit slides onto the lower flanges of an Lbeam or other similar support structure. Each of the hanger plates are still further provided with at least one support This type of construction has often resulted in 7 3,181,487 i atented May 4, 1965 peg which coacts with a peg-receiving hole formed in the corresponding face surface of the refractory anchor. Preferably two such pegs are provided on each hanger plate, one at each of its lower corners.

The pegs which engage the refractory anchor and the support lugs which engage the openings in the hanger plates provide essentially a three-point suspension of the refractory anchor on the hanger plate. One advantage of this three-point suspension is the distribution of the load carried by the refractory anchor over a greater cross sectional area of the anchor. A substantial portion of the load on the refractory anchor is transmitted to the hanger plates at the center of the anchor so that little if any bending shear is applied to any portion of the anchor. The pegs set off-center in the corners of the hanger plates add stability to the hanger assembly as well as carrying a portion of the load.

The invention further contemplates that the face surfaces may be recessed. The hanger plates fit into the recesses to provide a flusher outer surface on the hanger assembly. This intact construction permits the entire hanger assembly to be pro-assembled and shipped to the job site as a compact, single-piece unit.

Accordingly, an object of the present invention is to provide a new and improved hanger assembly for supporting and anchoring a monolithic roof construction wherein in the hanger assembly is compact and effectively a single-piece uni-t.

Another object of the present invention is to provide a new and improved hanger assembly wherein a substantial portion of the load carried by the refractory anchor is transmitted to a hanger plate assembly substantially at the center of the anchor.

An additional object of the present invention is to provide a new and improved hanger assembly wherein the load carried by the anchor is transmitted to the hanger plates through a maximum possible cross-sectional area of the anchor and wherein such area is under a minimum of shear.

Yet another object of the present invention is to pro vide a new and improved hanger assembly wherein the refractory anchor transmits its share of the load to the hanger plate through essentially a three-point suspension.

Still another object of the present invention is to provide a new and improved hanger assembly wherein the refractory anchor is not subject to breakage at the point Where it transmits its share of the load to the metallic member securing the refractory anchor to the support structure of the particular unit in which the monolithic refractory construction is being used.

Other objects and a fuller understanding of the invention may be had by referring to the following description and claims taken in conjunction with the accompanying drawings in which:

FIGURE 1 is a perspective view showing the hanger assembly of the invention in an exploded relationship;

FIGURE 2 is a front elevational View showing the hanger assembly of FIGURE 1 in use and carried by a structural I-beammember; and

FIGURE 3 is a sectional view of the taken along lines 3-3 of FIGURE 2.

Referring now to the drawings, a hanger assembly for supporting a monolithic refractory roof construction is indicated generally by the reference character 11. The hanger assembly 11 includes a refractory anchor 12 and a pair of hanger plates 13, 14.

The refractory anchor 13 is preferably formed from a suitable refractory material. The type of refractory material depending upon the particular application in which the hanger assembly is to be used. A lower, anchoring portion of the refractory anchor 12 is notched hanger assembly structure with a packing technique the f of anchor 12 is essentially a blindside.

plastic refractory .to pack plastic refractory on recessed faces 23,

on three sides 15, 16 and the ribs 19. A second set of the ribs 20 project from a fourth side 18 of the refractory anchor 12. The ribs 19, 20 provide anchor surfaces around which a monolithic refractory material is cast or pneumatically packed to construct a furnace roof. The ribs 19, 20 also provide a line along which the refractory anchors may be cut to various-lengths to suit roof thicknesses and tapers de-' sired.

When the anchor assembly 11 is used to form a roof fourth side 18 That is, a work- .man packing the plastic refractory material around the hanger assemblies 11 faces side 16 of anchor 12. Since side 18 is blind it is almost impossible to tightly pack the plastic refractory material behind the anchor 12. To solve this problem the workman isprovided with a metal template to make rib impressions in the plastic refractory material. The metal template has ribs similar to those of the refractory anchor to be imbedded in the material. At each hanger location rib impressions are made in the thus far packed plastic refractory material bythe metal template. The refractory anchor is then placed in position with the blind side ribs snuggly received in the rib impressions made by the template. This procedure substantially eliminates having the blind side of the anchor. The anchor of the invention is especially suited for use in the above pneumatic packing procedure. At best shown in FIGURE 3 the ribs 20 project from side 18 and are not formed by notching as were the ribs 19 on sides .15-17. Hence, a template need only make impressions for the ribs 20 and not for the upper hanger portion of .the anchor 12. In addition the force on the template is concentrated on the template ribs so that the rib impressions are quickly made with deep and accurate outlines. Where the roof is cast the template is not required and the blind side may be identical to the opposite side 16.

The ribprojections 20'forrn on the blind side 18 of the anchor present no problem during packing as they are opposite the notches forming ribs'19 on the side 16. When the hanger assemblies are packed for shipment the ribs 20 fitinto the notches to tightly pack and conserve space during storage and shipping.

An upper, hanger portion of the anchor 12 includes recessed face surfaces 23, 24 formed in sides 16, 18. The 24 are sized and dimensioned to receive the hanger plate 13, 14. As shown in FIGURE 3, the hanger plates 13, 14 fit substantially flush with the surfaces of sides 16, 18.

Lug projections 25, 26, protrude from the recessed faces 23, 24. The lug projections 25, 26 are contoured somewhat in the form of an inverted bell and include bearing surfaces 21, 22 respectively.

-A support-receiving groove 27 extends between the recessed surfaces 23, 24. The groove 27 is substantially T- shaped and is defined on its sides by a pair of inwardly extending elongated protrusions 28, 29. The elongated 29 are sized and spaced to receive the protrusions 28, flanges and .web of an I-beam 30 as shown in FIGURE 2.

The hanger plates 13, 14 are made of a metal, preferably a steel alloy. The hanger plates 13, 14 include inner 17 in several places to form 4" f face surfaces 23, 24. The pegs 37, 38 engage the top portions of the support holes 39, 40 and carry a portion of the weight on the anchor 12.

The hanger assembly 11 providesessentially three-point suspension between each of the plates 13, 14 and the refractory body. The first point of suspension is where the bearing surfaces 21, 22 of the lug projections 25, 26 engage the surfaces 31, 32 defining the openings in the hanger plates 13, 14. The rounded belllike surfaces 21, 22 of the lug projections 25, 26 and of the surfaces 31, 32 provide maximum bearing surface contact between them. The second and third points of suspension are provided by co-action between. the pegs 37, 38 on the plate hangers 13, 14.and the support holes 39, 40 made in the recessed 'faces 23,. 24. l

Because of the relatively wide tolerances in refractory bricks, the support holes 39, 40 are made somewhat larger than the support pegs 37, 38 which they receive. This is to assure that the principal support of the hanger plates is by the bearing surfaces 21, 22. As the refractorybody settles somewhat relative to the plates the pegs 37, 38 come into supportive engagement with the-walls of the holes 39, 40 to provide the described three point susprojections 25, 26, respectively. The openings defined by the surfaces 31, 32 conform closely to the bell-like shape of the lug projections 25, 26. The hanger plates 13, 14 further include tab portions 33-36. The tab portions 33- 36 align with the inwardly extending, groove defining protrusions 28, 29 when the hanger plates 13, 14 are positioned against the recesses faces 23, 24. The tab portions 33-36 rest on the inside of the flanges of the I- beamv 30'to carry the load on the. anchor 12. Support pegs 37, 38 project from the lower corners of the hanger plates, 13, 14. The pegs 37,38 are received in support holes 39, 40 formed in the lower corners of the recessed pension.

The hanger plates 23, 24 by an adhesive or other suitable means prior to shipment'tothe job site. Since the hanger plates are somewhat integral with the anchors 12 the hanger assembly 11 pack neatly into very tight shipping units. Thus, it is not necessary to ship separately the hanger plates and the anchor and then assemble them at the job site.

In summary the hanger assembly of the present invention has:

(1) A refractory anchor body having a lower ribbed anchor portion and an upper hanger portion;

(2) Lug projections which protrude from opposite sides .of the hanger portion of the refractory anchor.

(3) A pair'of hanger plates having openings which receive the lug projections. r

(4) The plates having at least one peg projection coacting with a hole in the hanger portion of the refractory anchor to provide additional support.

(5) Portions of said hanger plates and of the refractory anchor define a groove for receiving a shaped portion of a supporting structure. I

Although the invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention as hereinafter claimed.

What is claimed is:

1. A hanger for anchoring and supporting a refractory material in a monolithic form from a support structure having hanger supporting flange means; said hanger comfrom opposite sides of said hanger plates defining a groove sized and shaped to slidably receive the flange means of the support structure.

2. A hanger for anchoring and supporting a refractory material in a monolithic form from asupport structure having hanger supporting flange means, said hanger comprising: 1

(a) an anchor-bodyhaving a ribbed anchor portion and a hanger portion;

13, 14 may be secured to the faces (b) lug projections protruding from opposite sides of said hanger portion;

(c) a pair of hanger plates, one adjacent each of said opposite sides, said hanger plates including surfaces supportably engaging said lug projections;

(:1) said hanger plates each including peg projections spaced from and on opposite sides of the surfaces engaging the lug projections;

(2) said hanger portion of the anchor body including holes for receiving pegs, said pegs coacting with said holes to provide supporting engagement between said anchor body and said hanger plates in addition to that between the lug projection and the lug projection engaging surfaces; and,

(f) aligned portions of both said anchor body and said hanger plates defining a groove sized and shaped to slidably receive the flange means of the support struc- Y ture. 3. A hanger for suspending refractory material in a 6 said projections including curved support surfaces; (c) first and second hanger plates disposed adjacent said first and second faces respectively; (at) said hanger plates including:

(i) tab portions aligned with said pair of inwardly extending protrusions, and,

(ii) openings receiving said projections, and said openings being defined in part by curved plate surfaces engaging like curved portions of the support projections.

6. A hanger for suspending packed refractory material a monolithic construction from a support structure having oppositely extending flanges, the hanger comprising:

(a) an anchor body having a hanger portion and a ribbed refractory carrying portion; (b) said hanger portion having (i) first and second oppositely disposed side faces,

said side faces being recessed,

monolithic roof construction from a support structure having oppositely extending flanges, the hanger comprising (ii) a pair of inwardly extending elongated prosions defining flange-receiving grooves extending between said faces, and,

(a) an anchor of refractory material; (b) said anchor having an upper hanger portion and a (iii) first and second lug projections protruding from said first and second faces, respectively;

lower ripped portion; said projections including curved support sur- (c) said ribbed portion having projecting surfaces for faces;

carrying the plastic refractorymaterial; (c) first and second hanger plates disposed adjacent (at) said hanger portion including center lu'g projections said first and second faces, respectively, said plates on opposite sides of said anchor; sized to fit Within the recesses and substantially flush (e) hanger plates adjacent each of said opposite sides with the anchor side surfaces;

and including openings receiving said lug projections; (d) said hanger plates including (1) said projections engaging portions of said projec- (i) tap portions aligned with said pair of inwardly tion-receiving openings; and, extending protrusions,

(g) each of said plates including a pair of inwardly di- (ii) projection-receiving openings receiving said rected tab portions each adapted to rest on the inside lug projections, and said openings being define of one of the oppositely extending flanges of the supin part by curved plate surfaces engaging the port structure, and the tab portions of one plate alignk curved portions of the support projections; ing with the tab portions of the other plate to define and groove ends adapted to slidably receive the flanges (c) ai anger plates and said anchor including said of the support structure, 0 lug projections as received in said openings providing 4. A hanger for suspending packed refractory material in a monolithic roof construction from a support structure, the hanger comprising;

(a) an anchor of refractory material;

(15) said anchor having an upper hanger portion and a a substantially even surface. 7. A hanger for suspending packed refractory material a monolithic construction from a support structure having oppositely extending flanges, the hanger comprising:

(a) an anchor body having a hanger portion and a lower ribbed portion; ribbed refractory carrying portion;

(0) said ribbed portion having projecting surfaces for Said hanger Portion having carrying the refractory material; (i) first and second oppositely disposed recessed (d) said hanger portion including center lug projections Side faces,

on opposite side of said anchor; (ii) a pair of inwardly extending elongated protru- (e) hanger plates adjacent each of said opposite sides sions defining a supp t Structure receiving and including openings receiving said lug projections; groove amending between Said faces,

( said projections resting on portions of said lug profirst and Second pp Projections P jection-receiving openings; ing from said first and second faces, respectively,

(g) each of said hanger plates including pegs located said projections including curved support surbelow and elf-center of said projection-receiving faces, and p i (iv) support holes in said faces;

( silldfinchol' hill/{11g 119165 f Tecelvlng salfi Pegs, (c) first and second hanger plates disposed adjacent and said pegs coacting with said holes to provide supi fi t and second faces respectively; gloarttesejiagigement between the anchor and the hanger 1 a hinger lijlates i g (i) said plates including means for securing said hanger (1) goiuonstahgnmg with sald Palr 0f inwardly assembly to the support structure. fl en pro 5. A hanger for suspending packed refractory material (11) prolectmli-reirewmg .opemnfgs rece.1vmg Bald a monolithic construction from a support structure havupport projections Sald Openmgs being efined ing oppositely extending flanges, the hanger comprising: part by f plate surfaces engagmg. the

(a) an anchor body having a hanger portion and a like curved portions of the support pro ections,

ribbed refractory carrying portion;

b i hanger Portion having; (iii) support pegs, extending into said support- (i) first and second oppositely disposed side faces, 7 holes; and,

(ii) a pair of inwardly extending elongated protruthe pp Pegs, the Curved Plate Surfaces, The P sions defining flange receiving grooves extending receiving holes, and the curved support surface of the between said faces; and, projections being suitably located so that the load is (iii) first and second lug projections protruding carried by the hanger plates on the curved plate surfrom said first and second faces, respectively, faces and on said pegs.

8. A hanger for anchoring and supporting a refractory material in a monolithicform from a support structure having hanger supporting flange means, said hanger comprising: V

(a) an anchor body having a ribbed anchor portion and a hanger portion including protruding parts;

(b) a hanger plate abutting the hanger portion;

(c) portions of said hanger plate supportably engaging the protruding parts of said hanger portion; and,

(d) aligned portions of both said refractory anchor and said hanger plate defining a groove sized and shaped to slidably receive the flange means oflthe support structure.

9. A hanger for anchoring and supporting a refractory material in amonolithic form from a support structure having hanger supporting flange means, said hanger comprising:

(a) an anchor body a hanger portion;

(1)) said hanger portion including lug projection means;

(c) a hanger plate abutting the hanger portion;

(d) portions ofsaid hanger plate supportably engaging said lug projection means; and, V

(e) aligned portions of both said refractory anchor and said hanger plate defining a groove sized and shapedto slidably receive the flange means of the support structure.

a 10. A hanger for suspending packed refractory material in a monolithic roof construction from a support structure, the hanger comprising: 7

(a) an anchor member of refractory material;

(b) said anchor member having a hanger portion and a ribbed portion; I

(c) said ribbed portion having projecting surfaces for carrying the packed refractory material;

(d) a hanger plate membertabuttin g the hanger portion of said anchor member; I

(e) the members each including surfaces defining a support projection and surfaces defining a vertically spaced support projection receiving opening, the support projection of one member being received within 7 the projection receiving opening of the other member;

(f) the-projection surfaces and'their mating projection receiving opening surfaces being adapted to'engage when the hanger is in use;

(g) the vertical spacing between the opening and projection surfaces of one member being greater than such spacing on the other member whereby the members are adapted so that the engagement surfaces of one projection and its projectionreceiving opening having a ribbed anchor portion and CID . r i are in engagement andthe engagement surfaces 0 the other projection and its mating projection receiving openingare spaced'from engagement when the members are assembled prior tense, and the spaced engagement surfaces of said other projection and its mating projection receiving opening come into engagement as the refractory material of the anchor member settles duringruse; and,

(h); said plate'member including means for securing said hanger'assembly to the support structure.

11. Ahanger for suspending packed refractory material in, a monolithic roof construction from a support structure/the hanger comprising:

(a) ananchor member of refractory material;

(b) said anchor having ahanger portion and a ribbed portion; 7 a p p L (c) said ribbed portion having projecting surfaces for carrying the packed refractory material;

(d) a hanger plate member abutting the hanger portion of said anchor member; I (e) said members including three projections and three coacting openings having interacting support surfaces forvertical support of the anchor member by the plate member;

one projection surfacerand one of the opening sur- '7 faces coacting therewith being vertically spaced from another, projection surface and another of the opening surfaces coacting therewith;

(g) a first of said one and a first of said other surfaces being on one of the members;

(h) a second of said one and a second of said other surfaces being on the other of said members;

(i) the vertical spacing of the first surfaces being greater than the vertical spacing of the second surfaces; and, V j V said plate member including means for securing said hanger assembly to the support structure.

References (Zited by the Examiner UNITED STATES PATENTS 1,978,077 10/34 Doyle et a1.

2,524,721 10/50 Weber et al -99 2,664,836 1/54- RaWlings 1lO99 3,019,561 2/62 Weber 1l0--99 X 3,045,994 7/62 Longenecker 110-99 X 3,056,362 10/62 'Hosbein et al. 110-99 IAMES W. WESTHAVER, Primary Examiner.

FREDERICKKETTERER, Examiner.

UNITED STATES PATENT OFFICE CERTIFICATE ()F CORRECTION Patent No. 3 ,l8l,487 2 May 4 1965 Andrew J. Darke It is hereby certified that error appears in the above numbered patent requiring correction and that. the said Letters Patent should read as corrected below.

Column 1, line 22, before "in" insert sometimes column 2, line 27, strike out "in"; column 5, line 25, for "ripped" read ribbed column 6, line 8, before "projections" insert lug lines 20 and 21, for "prosions' read protrusions Signed and sealed this 26th day of October 1965.

(SEAL) Auest:

ERNEST W. SWIDER EDWARD J. BRENNER Attesting Officer Commissioner of Patents 

1. A HANGER FOR ANCHORING AND SUPPORTING A REFRACTORY METERIAL IN A MONOLITHIC FORM FROM A SUPPORT STRUCTURE HAVING HANGER SUPPORTING FLANGE MEANS; SAID HANGER COMPRISING: (A) AN ANCHOR BODY HAVING A RIBBED ANCHOR PORTION AND A HANGER PORTION; (B) LUG PROJECTIONS PROTRUDING FROM OPPOSITE SIDES OF SAID HANGER PORTION; (C) A PAIR OF HANGER PLATES, ONE ADJACENT EACH OF SAID OPPOSITE SIDES, SAID HANGER PLATES INCLUDING SURFACES SUPPORTABLY ENGAGING SAID LUG PROJECTIONS; AND, (D) ALIGNED PORTIONS OF BOTH SAID ANCHOR BODY AND SAID HANGER PLATES DEFINING A GROOVE SIZED AND SHAPED TO SLIDABLY RECEIVE THE FLANGE MEANS OF THE SUPPORT STRUCTURE. 